Electrical coil assembly

ABSTRACT

An electrical coil assembly having cup core coils and a pair of side flanges defining the coil member winding space and one of these side flanges is radially wider than the other and exceeds the circumference of the cup core coaxially surrounding the coil member. The widened peripheral flange part is only connected with the winding drum and has pliable metal studs fixed to the widened flange part which are displaceable in a direction transverse to the axis of the coil member.

Unite Reithmaier States Patent [191 [451 Jan. 7, 1975 ELECTRICAL COIL ASSEMBLY [75] Inventor: Egon Reithmaier, Gauting, Germany [73] Assignee: Siemens Aktiengesellschait, Berlin & Munich, Germany 22 Filed: Mar. 7, 1974 211 Appl. No.: 449,011

[30] Foreign Application Priority Data Mar. 7, 1973 Germany 2311312 [52] US. Cl 336/83, 336/192, 336/198 [51] Int. Cl. I-I0lf 15/02 [58] Field of Search 336/83, 212, 192, 198,

[56] References Cited FOREIGN PATENTS OR APPLICATIONS 1,180,923 2/1970 Great Britain 336/83 Primary Examiner-Thomas J. Kozma Attorney, Agent, or FirmHill, Gross, Simpson, Va'n Santen, Steadman, Chiara & Simpson [5 7] ABSTRACT An electrical coil assembly having cup core coils and a pair of side flanges defining the coil member winding space and one of these side flanges is radially wider than the other and exceeds the circumference of the cup core coaxially surrounding the coil member. The widened peripheral flange part is only connected with the winding drum and has pliable metal studs fixed to the widened flange part which are displaceable in a direction transverse to the axis of the coil member.

3 Claims, 1 Drawing Figure ELECTRICAL COIL ASSEMBLY BACKGROUND OF THE INVENTION This invention is directed to an electrical coil assembly including a coil member carried within a cup core coil which coil member has side flanges provided for the limitation of the coil member winding space whereby one is radially wider than the other and exceeds the circumference of the cup core which coaxially surrounds the coil member. The widened flange defines openings for the cup core and also serves as a means to support connecting studs for the ends of the wire windings. The connecting studs are bendable but are initially fitted in the widened flange in a direction parallel to the axis of the coil member.

Coil members for cup core coils are required in large numbers for use, for instance, as channel filter coils in carrier frequency transmission systems. For the electrical connection of the coil windings the winding ends are soldered to the connecting studs and the studs have their ends turned away from the coil in openings of conductor plates whereby the coil member is connected with a carrier plate in mechanical fashion. Due to the large number of required coils it has been found desirable to have the coil members designed so that they can be wound automatically be mechanical winding devices and to automatically be able to fix the winding ends'to the connecting studs.

SUMMARY OF THE INVENTION In accordance with the present invention the widened flange herein and above referred to and which is located outwardly of the cup core is only connected with the inner flange part of the coil member (that is with the winding drum) by pairs of bridges running in a lateral direction and formed integrally with the winding drum and with the widened flange. The bendable metal connecting studs are fixed in the widened flange along its periphery and a shoulder of that flange is displaced in an axial direction from the plane of the flange itself whereby the ends of the pliable metal studs at which the winding ends are fixed prior to winding of the coil member can be bent in a direction transverse to the axis of the coil member and below the plane of the widened flange itself whereby unobstructed axis to the winding space of the coil may be had.

In this manner an automatic connection of the winding ends at the angular ends of the connecting studs is possible and subsequent brazing of the winding ends to the connecting studs can be effected.

One feature of the invention pertains to the arrangement wherein the bridge pairs are extended outwardly so as to provide projections or noses which overhang the axially displaced shoulder supporting the connecting studs so that the winding ends can be held between these pairs of noses or projections and kept out of the cup core spaces by the winding drum and the enlarged flange. This feature assures a secure guiding of the winding ends from the winding spaces of the coil member to the connecting stud so that during closure of the cup core over the coil member a winding wire cannot be jammed, torn off or damaged. The projecting parts of the coil member moreover make it possible to attach a plastic housing between two such coil members in a simple manner with a conductor plate by having the projections extend to corresponding recesses in the base plate of a housing.

It is therefore an object of the present invention to provide a coil member of the type herein described wherein the coil member can be automatically wound and the winding ends can be automatically fixed to connecting studs and wherein cup core coils can be readily fitted over the coil member.

It is a further object of the invention to provide such a coil assembly wherein the connecting studs can be bent over it at an angle transverse to the axis of the coil forming a shouldered support below the plane of one of the two flanges of the winding drum thereby to give unobstructed access to the wire drum.

A still further object of the invention resides in the provision of a coil assembly herein described wherein pairs of bridges run in a direction transverse to the axis of the wire drum and project slightly above the stud support shoulder to provide a means for guiding the winding ends from the drum to the connecting studs while maintaining the windings out of the cup core space.

These and other objects, advantages and features of the present invention will be discussed in further detail with reference to the drawing.

The drawing submitted herewith illustrates in per- 'spective, exploded fashion an electrical coil assembly constructed in accordance with the principles of this invention.

With reference to the drawing, a spool type coil member 8 is shown as having a winding drum 10 providing a winding space for accepting the spirally wound wires 11. The winding space is defined at its upper and lower ends by side flanges 9 and 1, respectively. The side flanges and the winding drum itself consist of a plastic injection molded part and all three elements are integral with one another. The coil member 8 is designed so that it can be enclosed by a cup core which is coaxial with it and which is shown in the drawing as consisting of two core parts 12 and 13.

The lower flange 1 is coplaner with an enlarged flange portion 22 and is connected therewith by at least one pair of bridges 3 and cooperates with the innermost lower flange 1 to define an annular cup core opening 17. A stepped shoulder 15 is formed integrally with the enlarged flange portion 22 but is displaced axially below it and provides a support having a series of connecting pairs or studs 5. The connecting studs normally extend in a direction parallel to the axis of the winding core and are bendable in the fashion shown by the lefthand most pair in the drawing. The connecting studs 5 extend through the shoulder 15 and are adapted to be electrically connected with a conductor plate.

Preferably, the innermost flange 1 is interconnected with the enlarged flange portion 22 via two pairs of bridges 3 (only one being visible in the drawing) and consequently the cup core half 13 is provided with only two slot-like recesses 14 which are dimensioned so as to fit snugly over the bridge pairs. Likewise, the thickness of the arcuate walls in cup core 13 corresponds to the thickness of the slots 17.

In order to achieve unobstructed access to the winding space 10 of the coil member during winding operation the studs 5 are supported by the shoulder 15 which lies in a place displaced axially from the surface of flange 22 so that when the studs are bent over as shown in the drawing the entire stud end will lie below the plane of flange 22.

The bridges 3 of each bridge pair provide restricted wire guide channels 4 for routing the wires from the winding position to the connecting studs in order to assure that no wires will accidentally be positioned within the area of the arcuate core opening 17 in order to assure that the wire will not be damaged when the two core parts are mated together.

In addition, the bridges 3 have their outermost ends extending a small amount above the shoulder 15 (to define small noses or projections) so that the wire ends will be held within the restricted channels 4 as they are guided to the respective studs.

As already observed, the stud ends extending below the flange 22 are adapted to extend into openings of a conductor plate (not illustrated) which is seated in section 19 of the base plate 20 which may, for instance, comprise a portion of the housing 21 for mechanical swing elements so that during the attachment of the coil member at a conductor plate the coil member at the same time constitutes the attached member for an additional housing.

In the down turned position of the stud ends (that is when they are displaced transversely to the axis of the coil) a simple attachment of the winding ends is made posible, for instance, by means of the same winding device used for the winding of the coil member itself. The angular ends of the connecting studs can subsequently be submerged into a solder bath whereby the winding ends are soldered to the connecting studs. If the bent ends of the connecting studs are thereafter bent back to a position parallel to the axis of the coil, the winding ends now soldered to the connecting studs will run entirely tension free to the coil member.

I claim as my invention:

1. An electrical coil assembly having cup core coils comprising a winding drum having outwardly extending flanges formed at opposite ends thereof for restriction of a core member winding space wherein one of said flanges is relatively wider than the other and lies in a plane transverse to the axis of'said drum and exceeds the circumference of the cup core coaxially positionable over the coil member and wherein said widened flange provides openings for said cup core and serves as a seat for connecting studs extending through the flange and lying in an axis parallel to the axis of said cup core, a pair of bridges interconnecting said widened flange and said drum and providing the only means for interconnecting the widened flange and said drum, wherein said cup core extends over said drum and through the spaces between said drum and said widened flange portion and wherein said interconnecting studs are displaceable in a direction transverse to the axis of said drum.

2. An electrical coil assembly constructed in accordance with claim 1 wherein said connecting studs are carried in a shouldered portion of said flange which shouldered portion is displaced from the surface of said widened flange serving as a restriction for one end of the winding space of said drum and wherein said winding studs can be bent transverse to the axis of said drum on said shouldered support so as to lie below the plane of the remainder of said widened flange.

3. An electrical coil assembly constructed in accordance with claim 2 wherein said pairs of bridges extend radially above said shouldered portions of said flange providing means for guiding the winding ends to said connecting studs. 

1. An electrical coil assembly having cup core coils comprising a winding drum having outwardly extending flanges formed at opposite ends thereof for restriction of a core member winding space wherein one of said flanges is relatively wider than the other and lies in a plane transverse to the axis of said drum and exceeds the circumference of the cup core coaxially positionable over the coil member and wherein said widened flange provides openings for said cup core and serves as a seat for connecting studs extending through the flange and lying in an axis parallel to the axis of said cup core, a pair of bridges interconnecting said widened flange and said drum and providing the only means for interconnecting the widened flange and said drum, wherein said cup core extends over said drum and through the spaces between said drum and said widened flange portion and wherein said interconnecting studs are displaceable in a direction transverse to the axis of said drum.
 2. An electrical coil assembly constructed in accordance with claim 1 wherein said connecting studs are carried in a shouldered portion of said flange which shouldered portion is displaced from the surface of said widened flange serving as a restriction for one end of the winding space of said drum and wherein said winding studs can be bent transverse to the axis of said drum on said shouldered support so as to lie below the plane of the remainder of said widened flange.
 3. An electrical coil assembly constructed in accordance with claim 2 wherein said pairs of bridges extend radially above said shouldered portions of said flange providing means for guiding the winding ends to said connecting studs. 